Cushman HAULER 800X Technician's Repair And Service Manual page 128

DIRECTION SELECTOR
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
DIRECTION SELECTOR
Before removing a suspected faulty micro switch,
ensure the electrical wires are firmly attached and the
wire is in good condition.
Removing Direction Selector
Tools List
Torque Wrench, in. lbs................................................. 1
Ratchet ........................................................................ 1
Socket, 7/16" ............................................................... 2
Socket, 5/16" ............................................................... 1
Wrench, 7/16" .............................................................. 2
Wrench, 5/16" .............................................................. 1
Phillips Screwdriver ..................................................... 1
Digital Volt Ohm Meter (DVOM) .................................. 1
Always observe the following warnings when working on or
near batteries:
To prevent an electrical arc that could cause
an electrical explosion, be sure that the key
switch is off and all electrical accessories are
turned off before starting work on vehicle.
Never disconnect a circuit under load at a bat-
tery terminal.
T h e b a t t e r y n e g a t i v e ( - ) c a b l e m u s t b e
removed before starting work on vehicle.
tery, which could result in an explosion and
severe personal injury or death.
Prior to removing the direction selector switch from the
body, the battery negative cable must be disconnected
to prevent the possibility of electrical spark or 'shorting
out' the battery, either of which could result in an explo-
sion and severe personal injury or death.
Remove screw (1) securing the handle (2) to the direc-
tion selector shaft, and remove handle (Ref. Fig. 1).
Loosen the hardware (3) attaching the direction selector
bracket (4) to the seat frame and remove direction
selector from body.
Page K-2
Wrap wrenches with vinyl
tape to prevent the possi-
bility of a dropped wrench
from 'shorting out' a bat-
Repair and Service Manual
Replacing a Micro Switch
To replace a micro switch (5), remove the attaching
hardware (Ref. Fig. 1). Carefully remove the two electri-
cal wires from the switch. Reattach the wires to the new
switch. Using a DVOM, test the switch to ensure it is
operational before continuing. Once it is determined that
Qty.
the switch is functional, continue reassembly of micro
switch to the direction selector and installing to body.
Connect wires attaching to the switch and the screws
(6), nuts (7) and washers (8) attaching the switch to the
assembly to 8 - 11 in. lbs. (0.7 - 0.9 Nm) torque.
Shift Cable Adjustment
The single cable direction selector is a mechanical
device that operates a cable connected to the rear axle
(Ref. Fig. 1). The cable is sealed and does not require
lubrication. Required adjustment should be minimal.
Adjust threaded fitting (9) at forward cable mount while
selector is in the 'REVERSE' position until direction
selector cam will contact both stops, or contacts the
reverse stop and maintains no more than an 1/8" gap at
the 'FORWARD' stop. If further adjustment is necessary,
adjust threaded fitting (10) at the rear axle cable mount
(11). Lubricate the direction selector, linkage and related
moving parts periodically.
Neutral Lock Operation
The neutral lock is located on the direction selector. To
operate neutral lock located on the direction selector,
first turn the key switch to 'OFF', place direction selector
in 'R' and remove seat. Pull out (1) and rotate (2) the
neutral lock pin handle so that the pointed portion of the
handle is over the side of the direction selector cam
(Ref. Fig. 2). Move direction selector lever towards the
area between 'F' and 'R'. During that motion, the pin will
snap into the hole in the direction selector mounting
bracket, preventing any movement of the lever. When in
this position, the direction selector remains locked in the
neutral position.
Spring loaded mechanism. To prevent possibil-
ity of fingers becoming pinched in the direction
selector mechanism, hold direction selector
lever when releasing neutral lock pin handle.